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Publishable Final Activity Report Page 1 THE SIXTH FRAMEWORK PROGRAMME Priority 4: Aeronautic and Space, Call FP6-2005-Aero-1 RTD-Project: - HEATTOP – Contract no. AST5-CT-2006- 030696 Publishable Final Activity Report page 1 Project title: “Accurate High Temperature Engine Aero-Thermal Measurements for Gas-Turbine Life Optimization, Performance and Condition Monitoring” Project acronym: “HEATTOP” Contract number: AST5-CT-2006- 030696 Type of Instrument: STREP Publishable Final Activity Report Period covered: from August 01, 2006 to April 30, 2010 Issuing date: July 30, 2010 Start date of project: August 01, 2006 Duration: 45 months List of contractors: No Role Country Partner name Acronym 1 Coordinator, Germany Siemens SIE WP Lead 2 WP Lead U.K. Rolls Royce R-R 3 WP Lead Sweden Volvo Aero VAC 4 Switzerland Vibro-Meter CH VM-CH 5 U.K Vibro-Meter UK VM-UK 6 WP Lead Netherlands KEMA KEMA 7 Italy CESI RICERCA CESI-R 8 Ireland Farran FARR 9 WP Lead Belgium Von-Karman Institute for Fluid Dynamics VKI 10 U.K. Oxsensis OXS 11 Germany Advanced Optical Solutions AOS 12 France Auxitrol AUX 13 Germany Institute of Photonic Technology IPHT 14 U.K. Univ. Cambridge (2 depts : MAT & DENG) UCAM 15 Sweden Univ. Lund ULUND 16 France Onera ONERA 17 U.K. Univ. Oxford UOXF Project coordinator: Patrick R. Flohr Siemens AG, Energy Sector, Fossil Power Generation Coordinator email: [email protected], Telephone: +49-208-456-4757 Fax: +49-208-456-2773 Document name: HEATTOP Publishable Final Activity Report_6.doc Authors: Patrick Flohr & All Contractors THE SIXTH FRAMEWORK PROGRAMME Priority 4: Aeronautic and Space, Call FP6-2005-Aero-1 RTD-Project: - HEATTOP – Contract no. AST5-CT-2006- 030696 Publishable Final Activity Report page 2 1 Executive Summary........................................................................................................3 1.1 Purpose of this document.............................................................................4 1.2 Relationship to Project Objectives................................................................4 1.3 Intended Audience .......................................................................................5 1.4 Summary and Structure of the Document ....................................................5 2 HEATTOP Project Scope and Objectives .....................................................................6 2.1 Background ..................................................................................................6 2.2 Summary of Project Objectives ....................................................................7 2.3 Consortium ...................................................................................................9 2.4 Project Organization and Development Approach .....................................10 3 Performed Activities .....................................................................................................12 3.1 Definitions and Specifications, WP1...........................................................12 3.2 Technology Developments in WP2-WP5 ...................................................13 3.2.1 Life and accuracy optimization of current instrumentation for high temperature measurement, WP2........................................................................13 3.2.2 Advanced Solid Temperature Measurements, WP3 ..............................26 3.2.3 Gas path aerodynamic measurements, WP4.........................................43 3.2.4 Tip Clearance measurement, WP5 ........................................................67 3.3 Validation of Technologies, WP6/7 ............................................................72 3.3.1 Validation approach................................................................................72 3.3.2 Validation planning .................................................................................73 3.3.3 Test Vehicle Selection............................................................................73 3.3.4 Vehicle Modification and Measurement Validation Testing ....................74 3.3.5 Validation status achieved......................................................................86 4 HEATTOP Publishable Results....................................................................................89 4.1 Overview of exploitable knowledge of HEATTOP ......................................89 4.2 Details of Publishable Results....................................................................92 5 Dissemination of knowledge .....................................................................................106 5.1 External dissemination .............................................................................106 5.1.1 Thermocouples design .........................................................................106 5.1.2 Surface temperatures...........................................................................106 5.1.3 Gas path aerodynamic measurements.................................................108 5.1.4 Tip clearance measurements ..............................................................111 5.1.5 Further dissemination...........................................................................112 5.2 Internal dissemination ..............................................................................112 5.3 Patent applications ...................................................................................114 6 Conclusions ................................................................................................................115 Document name: HEATTOP Publishable Final Activity Report_6.doc Authors: Patrick Flohr & All Contractors THE SIXTH FRAMEWORK PROGRAMME Priority 4: Aeronautic and Space, Call FP6-2005-Aero-1 RTD-Project: - HEATTOP – Contract no. AST5-CT-2006- 030696 Publishable Final Activity Report page 3 1 Executive Summary HEATTOP is a FP6 STREP project and stands for Accurate High Temperature Engine Aero-Thermal Measurements for Gas-Turbine Life Optimization, Performance and Condition Monitoring. Project costs are 8.8 M€ with an EU contribution of 5.2 M€ and 17 partners are involved. The project addresses the need for improved instrumentation to be used in development, design evaluation and performance monitoring of aero engines and industrial gas turbines for power generation. In the middle of interest are the hottest regions of engines, the combustors and HP turbines where temperatures reach 2000K. The temperatures affect directly engine efficiency and life time of components. As current sensors cannot be placed in the hottest regions, knowledge of conditions inside the turbine is gathered from outside measurements which are then extrapolated by using models and assumptions. Turbine parts and other hot gas components are very expensive, have a shorter life time due to heavy mechanical and thermal loads and are critical for engine reliability. Accurate knowledge of temperatures would be very beneficial in predicting their life time and verify the performance of a design. Other aerodynamic parameters as dynamic and static pressure and clearances affect efficiency, operation and health of an engine. Clearances between blade tips and inner turbine housing contribute to efficiency losses over the turbine and therefore are kept to be as small as possible while at the same time rubbing of blades with subsequent turbine failure must be avoided. Dynamic pressures need to be accurately measured to assure the mechanical integrity of the engine. The objective of the HEATTOP project was to develop accurate high temperature sensors for measurement of pressure, temperature and tip clearances. The consortium consists of 17 partners of different type, size and legal status and is led by Siemens: - Original Equipment Manufactures (OEM): Siemens, Rolls-Royce, Volvo Aero - Industrial Partners: Vibro-Meter CH, Auxitrol, KEMA, Vibro-Meter UK, Onera - Research Institutes and Academia: VKI, IPHT, ERSE and the Universities of Cambridge, Oxford and Lund - Small and Medium sized Enterprises: Oxsensis, AOS and Farran The new sensors will reduce the uncertainty und reduced reliability of measurements with conventional thermocouples and pyrometry surface measurement techniques or enable measurement where currently no practical technique exists. A more accurate knowledge of temperatures may help to reduce consumption of cooling air and deliver a better prediction of life time and replacement needs. Clearances could be optimized when gaps are know accurately, leading to increased efficiency and reduced risk of damages. Document name: HEATTOP Publishable Final Activity Report_6.doc Authors: Patrick Flohr & All Contractors THE SIXTH FRAMEWORK PROGRAMME Priority 4: Aeronautic and Space, Call FP6-2005-Aero-1 RTD-Project: - HEATTOP – Contract no. AST5-CT-2006- 030696 Publishable Final Activity Report page 4 Volvo, Vibro-Meter, Auxitrol, Onera and Cambridge University worked on understanding the degradation mechanisms of thermocouples, manufacturing process improvements, and extension of temperature ranges towards 1500°C, thin film thermocouples and the development of fast response thermocouples. KEMA, Auxitrol and Vibro-Meter worked on pyrometer techniques and error correction methods for surface temperature measurement, University Lund investigated thermographic phosphors for measurement in an afterburner and Siemens together with IPHT and AOS developed fiber optic sensors (Fibre Bragg Gratings, Fabry Perot interferometer and Black Body Radiators) for temperatures up to 1200°C. Developed techniques for gas path temperature
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